windera s
PRODUCT MANUAL
windera s
PRODUCT
SMALL WIND POWER
SYSTEMS
OPERATION MODE
MANUAL
This Product Manual is codified with code I.H4.V10.3001.
2
EDITION
CHANGES
WHO
DATE
00
Initial edition
JCA
30/08/2013
01
Changes in section 6.2 and 8
MP
10/09/2014
Product Manual
windera s
PRODUCT
SMALL WIND POWER
SYSTEMS
CONTENTS
MANUAL
CONTENTS
1.
ABOUT ENNERA............................................................................................................................................................................................................................. 4
1.1. ABOUT SMALL WIND POWER SYSTEMS
4
1.2. WINDERA S
4
2.
ADVANTAGES OF SMALL WIND POWER SYSTEMS....................................................................................................... 5
3.
IMPORTANT SAFETY INSTRUCTIONS................................................................................................................................................... 6
4.
DECLARATION OF CONFORMITY TO STANDARDS........................................................................................................ 8
4.1. TURBINE-RELATED STANDARDS
8
4.2. CONVERTER-RELATED STANDARDS
8
5.WARRANTY..........................................................................................................................................................................................................................................13
6.
5.1. WHAT DOES IT INCLUDE?
13
5.2. WHAT IS NOT INCLUDED?
13
5.3. LIMITATIONS AND EXCLUSIONS
13
5.4. CUSTOMER RESPONSIBILITIES
14
SYSTEM DESCRIPTION .................................................................................................................................................................................................15
6.1. SMALL WIND TURBINE COMPONENTS
6.1.1.
Front cone
16
6.1.2.
Rotor
17
6.1.2.1.
Technical specifications
18
6.1.3.
Hub
19
6.1.4.
Generator
20
6.1.4.1.
Technical specifications
20
6.1.5.
Centrifuge brake
21
6.1.6.
Vane
22
6.1.7.
Yaw System
23
6.1.8.
Tower
24
6.1.8.1.
6.1.9.
3
15
Converter
Technical specifications
24
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8.
CONTENTS
MANUAL
6.1.9.1.
7.
SMALL WIND POWER
SYSTEMS
Technical specifications
26
6.1.10. Monitoring and communications
27
6.1.10.1. Financial information
27
6.1.10.2. Weather information 27
6.1.10.3. Technical and environmental information
28
6.2. OPERATION
29
6.2.1.
Emergency stop
30
6.2.2.
Controlled stop
31
6.3. WINDERA S GENERAL SPECIFICATIONS
31
COMPETITIVE ADVANTAGES AND INNOVATIONS.......................................................................................................32
7.1. COMPETITIVE ADVANTAGES
32
7.2. INNOVATIONS
32
INSPECTIONS AND MAINTENANCE........................................................................................................................................................33
8.1. VISUAL INSPECTIONS
33
8.2. NOISE INSPECTIONS
34
8.3. MAINTENANCE
34
9.TROUBLESHOOTING. ..........................................................................................................................................................................................................35
10.
FREQUENTLY ASKED QUESTIONS............................................................................................................................................................36
10.1. GENERAL QUESTIONS
36
10.2. TECHNICAL QUESTIONS
36
11.RECYCLING.............................................................................................................................................................................................................................................37
12.ANNEXES..................................................................................................................................................................................................................................................38
4
12.1. ELECTRICAL CONNECTION DIAGRAM
38
12.2. GENERAL DIMENSIONS DRAWING
39
Product Manual
windera s
PRODUCT
1.
SMALL WIND POWER
SYSTEMS
ABOUT
ENNERA
MANUAL
ABOUT ENNERA
Ennera is a renewable energy and sustainable mobility subsidiary of the CAF Group, a listed private company specialised
in the design, manufacture, maintenance and supply of railway system equipment and components.
Ennera's fundamental characteristic is its experience in offering renewable energy and sustained mobility solutions with
the maximum investment guarantee from an ecological perspective:
•
Ennera is a specialised business firm.
•
It has accumulated wide-ranging experience in providing customised solutions.
•
The company works with carefully selected and certified installers and suppliers.
•
Ennera satisfies customer requirements for the development of state-of-the art technological solutions for small
renewable energy systems and sustained mobility.
•
The company invests in research and development in order to offer the most advanced and highest quality
products.
•
It shows its concern for the environment by reducing environmental impact to a minimum.
1.1. ABOUT SMALL WIND POWER SYSTEMS
Wind power consists in transforming mechanical energy generated by wind into electrical energy by means of a rotor
equipped with permanent magnets.
Considering that wind is a free and unlimited resource, the Windera S solution capitalizes on terrain use to obtain the
most from it.
The main components of a small wind power system as follows:
•
Wind tower with a patented, innovative design.
•
Electricity generator.
•
Connection to the grid by means of the corresponding converter.
•
Monitoring system.
•
Emergency braking system.
The geometrics used by Windera have been designed to obtain maximum energy yield at wind speeds of between 4 and
10 m/s, with minimum noise.
Although the equipment involved is complex and large, Ennera guarantees safe and efficient installation, operation and
maintenance.
1.2. WINDERA S
•
Windera In:
This product model allows self-consumption of the generated energy. It provides the option of connecting the
installation in such a way that all the generated energy is reverted to the electrical grid of the home or business.
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Product Manual
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PRODUCT
2.
MANUAL
SMALL WIND POWER
SYSTEMS
ADVANTAGES OF
SMALL
WIND TURBINE
ADVANTAGES OF SMALL WIND POWER SYSTEMS
In addition to economic advantages, wind power implies significant environmental benefits because it is clean and
environmentally friendly.
These small wind power turbines do no emit radiation or interfere with their settings; their noise emission does not
disturb the tranquility and rest of either people or animals.
In sum Windera is an innovative technological and environmental solution that goes hand-in-hand with the sustainability
of the Earth, while obtaining the advantages inherent to generating one's own electricity.
With a hypothetical mean annual wind speed of 5 m/s at a height of 12 m over its foundation, the Windera S small wind
turbine, with a nominal power of 3.2 kW, can reduce CO2 emissions by 3 tonnes per year.
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3.
MANUAL
SMALL WIND POWER
SYSTEMS
IMPORTANT
SAFETY
INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS
The Windera system has been designed with your safety in mind. The Ennera team has given special priority to designing
its small wind turbine to comply with all safety regulations applicable to this type of machinery, as regards both its
mechanical and electrical features.
The system is equipped with overspeed protection to ensure that the small wind turbine does not exceed its maximum
rate of rotation, along with 50 alarms for early detection of failures and anomalies. These alarms are classified according
to their severity and return the turbine to safe operation. The alarms are also reported to a remote monitoring centre
from where maintenance tasks are organised. According to standard IEC 61400-2, the maximum wind speed that a Class
III small wind turbine should bear is 52.5 m/s.
Nonetheless, there are inherent dangers to any electrical or mechanical devices. It is necessary to be aware at all times
of both electrical and mechanical dangers as well as the danger posed by blade rotation and the following precautions
should be taken:
WHENEVER ACCESSING THE ROTOR, IT MUST BE IN EMERGENCY STOP STATUS.
THE STRUCTURE OF THE SMALL WIND TURBINE SHOULD BE HANDLED ONLY BY
TECHNICAL PERSONNEL.
MAKE SURE THAT THE TOWER IS GROUNDED AND THAT GROUNDING COMPLIES WITH
THE REQUIREMENTS IN THE LV MANUAL.
•
Mechanical hazards:
Blade rotation presents a very serious mechanical hazard. The rotor blades can reach speeds up to 280 rpm, which
are capable of inflicting severe injuries and damage.
DO NOT ACCESS THE ROTOR IF THE TURBINE IS IN OPERATION.
•
Electrical hazards:
The converter is an electrical device that operates at low voltage; the electrical hazards listed below for this type
of voltage should be heeded:
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MANUAL
SYMBOL
IMPORTANT
SAFETY
INSTRUCTIONS
MEANING
DANGEROUS ELECTRICAL VOLTAGE WARNING
THE INVERTER OPERATES AT HIGH VOLTAGES. ALL THE ELECTRICAL WORK ON THE INVERTER MUST
BE PERFORMED BY QUALIFIED ELECTRICAL INSTALLERS.
HOT SURFACE WARNING.
THE INVERTER CAN HEAT UP DURING OPERATION. DO NOT TOUCH THE INVERTER WHILE IT IS IN
OPERATION.
HEED ALL THE DOCUMENTATION SUPPLIED WITH THE INVERTER.
Low voltage electrical hazards can be caused by the following factors:
•
Two active conductors (phase-phase or phase-neutral) can short-circuit and act as a receiver connection.
•
Active and ground conductors can jump, either by direct contact with an active conductor or indirect contact via a
mass that is energised due to poor isolation:
•
Direct contacts: These are contacts with the active parts of the equipment that are designed to conduct
electricity (cables, plugs, busbars, sockets, etc.).
Indirect contacts: These are caused by touching certain parts that are not normally designed to conduct
electricity, but can be energised due a defect of some kind (metal parts or masses of equipment or
accessories).
A mass is subjected to the power difference between two masses or electricity-conducting components at
different voltages.
Make sure that the converter is grounded to ensure protection against indirect
electrical contact.
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4.
SMALL WIND POWER
SYSTEMS
MANUAL
DECLARATION OF
CONFORMITY
WITH STANDARDS
DECLARATION OF CONFORMITY TO STANDARDS
4.1. TURBINE-RELATED STANDARDS
•
IEC61400-2, Wind Turbines. Part 2: Design requirements for small wind turbines.
The international standard IEC61400-2 covers quality assurance features as well as the specific safety
requirements for small wind turbines, including design, installation, maintenance and operation in specific outdoor
conditions.
•
British Wind Energy Association: Small Wind Turbine Performance and Safety Standard, 29 February 2008.
•
MCS (Microgeneration Certification Scheme) Testing of Wind Turbine. www.microgenerationcertification.org.
•
Eurocode 3. Design of steel structures DS/ENV1993-1-1.
4.2. CONVERTER-RELATED STANDARDS
•
CE Marking – MQ Directive:
•
•
•
Connection to the grid:
Engineering Recommendation G83. Recommendations for the connection of small-scale embedded
generators (up to 16 A per phase) in parallel with public low-voltage distribution networks. ENA (Energy
Networks Association).
VDE 0126-1-1: Automatic disconnection device between a generator and the public low-voltage grid.
UNE-EN-50438: Requirements for the connection of small-scale generators in parallel with public lowvoltage distribution networks.
CE Marking – EMC Directive:
EN 61000-6-2: Electromagnetic compatibility (EMC). Part 6-2: Generic standards. Immunity in industrial
environments.
EN 61000-6-3: Electromagnetic compatibility (EMC). Part 6-3: Generic standards. Emission standard for
residential, commercial and light industrial environments.
EN 61000-3-2: Electromagnetic compatibility (EMC). Part 3-2: Limits. Limits for harmonic current emissions
(equipment input current <= 16 A per phase).
EN 61000-3-3: Electromagnetic compatibility (EMC). Part 3-3: Limits. Limitation of voltage changes, voltage
fluctuations and flicker in public low-voltage supply systems for equipment with rated current <= 16 A per
phase and not subject to conditional connection.
CE Marking – Low-voltage Directive:
•
IEC-61400-2, Wind Turbines. Part 2: Design requirements for small wind turbines.
EN 50178: Electronic equipment for use in power installations.
Labels:
There are different labels to measure noise and efficiency levels of the wind turbine so they can be easily compared
to other wind turbines.
The first label corresponds to the BWEA (British Wind Energy Association), Small Wind Turbine Performance and
Safety Standard.
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MANUAL
SMALL WIND POWER
SYSTEMS
DECLARATION OF
CONFORMITY
WITH STANDARDS
Figure 1. BWEA label: Noise levels.
This graph shows the noise level in relation to the distance the subject is at, as well as the wind speed registered in the
hub. The previous graph shows that noise perception decreases as the distance increases. The green area shows noise
levels below 40 dB(A).
The standards for maximum noise emission can vary according to the location because these are generally set by the
local authorities. In general terms, it is less likely for permission to be given for an installation located in the red area.
The locations that satisfy green area requirements are acceptable. Terrain located in the orange band may or not be
acceptable depending on a variety of factors, such as local or national legislation.
The points of reference of the noise marked in this map are 40 and 45 dBA, since these are generally significant levels
for planning wind power projects. The following table shows the noise levels associated with a variety of daily activities.
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SYSTEMS
DECLARATION OF
CONFORMITY
WITH STANDARDS
Figure 2. Noise levels: Daily activities.
Source: AWEA (American Wind Energy association, www.awea.org)
On the other hand BWEA has developed a label for annual energy production; this label indicates the energy for a mean
annual wind speed of 5 m/s.
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MANUAL
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SYSTEMS
DECLARATION OF
CONFORMITY
WITH STANDARDS
Figure 3. BWEA label: Energy certificate.
In addition, the International Energy Agency (IEA) has proposed a guide of recommended practices and tasks to be
drawn up by a group of experts from Sweden, Ireland and Spain, among others. Thus, a label has been developed based
on existing IEC standards accepted world-wide, instead of developing new standards that can only be applied in certain
countries. This label provides noise emission, performance and design safety information that is independent and easy
to compare.
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MANUAL
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SYSTEMS
DECLARATION OF
CONFORMITY
WITH STANDARDS
Figure 4. IEA Label: Noise emission, performance and design safety.
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5.
SMALL WIND POWER
SYSTEMS
WARRANTY
MANUAL
WARRANTY
Your Windera S installation meets the highest quality standards. The warranty period is subject to compliance with the
conditions and instructions specified in the warranty contract.
The warranty conditions indicated in this section are of an explanatory nature. The general warranty
conditions must be consulted in the warranty contract.
5.1. WHAT DOES IT INCLUDE?
•
The installation, including all the components, is free of manufacturing and installation defects. If this is not
the case, Ennera agree to replace any defective components free of charge for the user. Our technicians or an
authorised service centre will decide which part or parts are defective.
•
It is guaranteed that the power curve will not deteriorate further than established in the warranty contract under
normal operating conditions and following the maintenance recommendations included in the manuals.
•
Ennera reserves the right to replace or modify any of the parts if it deems it necessary to do so.
•
Access to the monitoring service of the facility.
5.2. WHAT IS NOT INCLUDED?
•
Damage by lightning.
•
Damage by extremely high winds. Extremely high winds are considered as those that exceed 52.5 m/s at the
height of the Class III hub, in accordance with IEC 61400-2. In principle, these gusts are rare in 50 year periods in
Class III environments with a mean speed of 7.5 m/s at the height of the hub (IEC 61400-2).
•
Grid-related disruptions outside the ranges considered as normal grid disruptions in EN50438.
•
Blade damage due to contact with other objects.
•
Damage caused by improper use of the facility or product.
•
Breakage due to mistreatment and equipment with proof of tampering.
5.3. LIMITATIONS AND EXCLUSIONS
14
•
Nobody shall have authorisation to make changes to this warranty.
•
All warranties applied to Ennera products are limited to the time period and conditions that appear in the warranty
document.
•
This warranty applies to the original purchaser and can be transferred.
Product Manual
windera s
PRODUCT
SMALL WIND POWER
SYSTEMS
WARRANTY
MANUAL
5.4. CUSTOMER RESPONSIBILITIES
All Ennera products must be installed and handled according to the user, product and installer manuals and according to
local engineering codes. If the turbine design is modified in any way, this will automatically render the warranty invalid
and compromise the safety of the product.
The company recommends that the purchaser keep a copy of the invoice or cancelled cheque to certify the date of
purchase.
Once the warranty expires, Ennera recommends that it be extended so the user can continue benefiting from the
complete services offered by the company, including access to monitoring and maintenance. This will achieve maximum
yield of the facility throughout its useful life.
For any other problems, doubts or suggestions, please contact Ennera at the toll-free number: 900 700 034 or via e-mail
at [email protected]
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6.
SMALL WIND POWER
SYSTEMS
SYSTEM
DESCRIPTION
MANUAL
SYSTEM DESCRIPTION
6.1. SMALL WIND TURBINE COMPONENTS
Figure 5. Windera Small Wind Turbine.
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DESCRIPTION
MANUAL
6.1.1. Front cone
The front cone is a shell coupled to the hub and the bases of the blades. Its purpose is to protect the hub and blade stems
from adverse weather conditions and to allow smooth wind entry at the base of each blade.
Figure 6. Front cone.
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DESCRIPTION
MANUAL
6.1.2. Rotor
The rotor system consists of three blades manufactured by a manual sheeting process with composite materials.
Specifically, the blades consist of a polystyrene core and outer sheeting composed of fibreglass, carbon fibre and epoxy
resin. Both the process and the materials that are used achieve very rigid, low-weight blades at all times.
The blades convert wind power into rotating energy that acts on the generator shaft. They use the same aerodynamic
principle as the wings of an airplane. The wind passes along the aerodynamic profile, generating high pressure on the
lower part of the blade and low pressure on the upper part. The difference in pressure generates a rotating torque in
addition to the force exerted on the rotor.
Figure 7. Rotor.
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DESCRIPTION
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The aerodynamic design of the Windera S blades is a combination of an aerodynamic profile that is especially adapted
to the operating parameters for blades of this size and a blade geometry that seeks to optimise the power produced at
moderate wind operating ranges. The result is a blade that has proven to be extremely efficient in both wind tunnel tests
and tests performed in the field.
Moreover, the rotor blades have an aerodynamic tip at the end (winglet) designed to reduce power loss at the wing tip,
thus increasing generated power without increasing blade diameter. The winglets are easy to distinguish due to their
similarity with those on airplane wings.
The blades are firmly attached to the generator shaft by means of the hub. Each set of 3 blades is carefully manufactured
to maintain the rotor in complete equilibrium and thus guarantee optimal operation of the Windera S small wind turbine.
6.1.2.1. Technical specifications
•
Configuration...................................................................................................................................................................................................... Upwind
•
Pitch.................................................................................................................................................................................................................................Fixed
•
Orientation....................................................................................................................................Free yaw moved by streamlined vane
•
Blade diameter.....................................................................................................................................................................................................4.36 m
•
Swept area...........................................................................................................................................................................................................14.9 m2
•
Material.....................................................................................................................................................Carbon fibre, fibreglass and epoxy
•
Process.............................................................................................................................................................................................. Manual sheeting
•
Start-up wind speed.......................................................................................................................................................................................3.5 m/s
•
Cut-out wind speed........................................................................................................................................................................................2.5 m/s
•
Maximum wind speed.....................................................................................................................................................................................25 m/s
In the event of wind speeds in excess of 25 m/s, Windera performs a controlled safety stop.
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DESCRIPTION
MANUAL
6.1.3. Hub
The hub is the part of the rotor system where the blades are inserted. The hub, located at the front of the wind turbine,
is the element on which the 3 blades are supported. As it is not equipped with a gearbox, it is connected directly and
transmits the wind torque generated by the wind through the blades to the generator shaft.
The hub is made of aluminium so it is very lightweight, but strictly calculated to operate in extreme wind conditions.
Figure 8. Hub.
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DESCRIPTION
MANUAL
6.1.4. Generator
The generator converts the rotation energy produced by the rotor system into electrical power.
This component is essential for the Windera S to be efficient and effective, since the efficiency of the energy
transformation depends on it. The generator design provides high electrical performance and a short start-up torque.
This has all been achieved by designing a permanent-magnet generator with an optimised pole-slot configuration and
the use of low-friction ball bearings. The number of magnets is always even and they move evenly in a circle so the poles
are magnetically alternated.
The generator is designed to produce the maximum amount of energy; its smooth start-up with minimal resistance
allows the wind turbine to continue producing electricity even at low wind speeds. The choice of a permanent-magnet
generator has the advantage of producing energy whenever the rotor system is rotating, regardless of how low the
rotation speed is.
Since it is capable of producing energy at low wind speeds, it eliminates the need to equip the Windera S with a gearbox
that increases the revolutions of the blade-hub unit. On the other hand, slow rotation speeds reduce both mechanical
stress and noise emissions.
In addition, the generator can exert its own braking force, activated by the converter when wind speeds are too high.
This brake is called a Crowbar brake.
Finally, the manufacturing process of the stator provides perfect cooling properties that contribute to increase the
performance of the Windera S.
Figure 9. Generator.
6.1.4.1. Technical specifications
21
•
Normal temperature range.............................................................................................................................-10ºC to +45ºC in nacelle
•
Rated speed.......................................................................................................................................................................................................230 rpm
•
Braking torque......................................................................................................................................................................2.5 x Tnom (approx.)
•
Maximum speed..............................................................................................................................................................................................280 rpm
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DESCRIPTION
MANUAL
6.1.5. Centrifuge brake
The centrifuge brake is a redundant safety device that stops the wind turbine in the event of emergencies. The braking
action is performed by moved by the centrifugal force of ferodo brake pads that press against the drum when speed is
at a maximum. This friction causes the system to lock and the wind turbine to stop. Once the turbine has stopped, the
pads return to their initial position and the wind turbine is braked by the crowbar.
The brake can be activated in the event of failures in the electrical grid or other abnormal emergency conditions in the
system. It is a redundant speed protection, since the crowbar is capable of stopping the wind turbine by itself under
normal operating conditions. System failures at very high wind speeds or a failure in the crowbar system can activate
the centrifuge brake. In normal conditions, the wind turbine is stopped by the electrical brake. If the wind conditions are
such that the electrical brake is not capable of braking the turbine, the centrifuge (mechanical) brake prevents it from
exceeding the maximum design speed and brings it to a stop.
Figure 10. Centrifuge brake.
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6.1.6. Vane
The vane is the component that orients the turbine towards the wind. It consists of a single part that is firmly attached
to the generator shell. As in most wind turbines with a horizontal shaft, it rotates around a bearing to face the wind.
The orientation axis is the vertical line that passes through the centre of the bearing and coincides with the tower axis.
Due to the small dimensions of the wind turbine, there is not enough space to house transmission mechanisms and
electrical motors that orient the rotor to face the wind. This is why the Windera S orientation system consists of a vane
so the wind can impel the blades from the front (upwind). Its innovative single-part design avoids the need for gaskets,
nuts and bolts, thereby increasing the aerodynamic properties of the whole.
The vane is located at the end of a rod and the wind exerts a lateral force on it to turn the turbine so that it faces the
wind. The moment affecting the vane is simply the lateral force multiplied by the length of the rod. The lateral force is
the result of the surface area of the vane and the wind speed squared.
Figure 11. Vane.
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DESCRIPTION
MANUAL
6.1.7. Yaw System
The Yaw unit is the system that contains the components that make it possible for the nacelle to rotate around the
tower axis in order to position itself facing the wind. The rotating system (Yaw) is found on all wind turbines. However,
while large wind turbines have complex systems consisting of gears and hydraulic systems, small turbines are generally
equipped with passive systems. This is the case of the Windera S.
The Yaw system and the vane are key elements in obtaining maximum efficiency, since they allow the wind turbine to
position itself with minimum turbulence and the rotor to draw the maximum power from the wind. The system consists
of the following components:
•
Yaw shaft.
•
Yaw chassis.
•
Set of yaw bearings.
•
Slip ring collector.
•
Set of silent blocks.
The slip ring collector consists of a set of 4 rings and 8 brushes of simple design. The low operating speeds of the yaw
allow the use of silver-graphite brushes with low contact resistance and reduced wear throughout their service life. The
yaw chassis allows access to the collector to check wear conditions during scheduled maintenance tasks.
The yaw is attached to the tower by a bolted connection separated by a set of silent blocks. The silent blocks isolate the
support structure from the vibrations in the nacelle, thus contributing to lower mechanical noise.
Figure 12. Yaw System.
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6.1.8. Tower
The tower is the structure that supports the turbine. It is 12 metres high and capable of withstanding extreme wind
conditions. It has been designed according to the load criteria found in standard 61400-2 and the guidelines found in
the Eurocode for support structures. It is made of galvanised steel sections that not only add to its elegance but protect
it against adverse weather conditions.
The tower consists of 4 sections with a total length of 12 metres once they are assembled. The sections can be
transported by 2 or 3 people without the need for cranes or external equipment. The sections are assembled on top
of each other, applying contact pressure between sections to ensure that each section inserts perfectly into the
previous one. It is also equipped with a guide system at the base to facilitate lowering the wind turbine during assembly,
disassembly or maintenance tasks. A hoisting and lowering system can also be mounted on the inside of the tower
to facilitate installation, uninstallation and maintenance, without the need to use cranes. This significantly reduces
customer expenses, increases profitability and allows assembly in areas that are difficult to access.
Figure 13. Tower.
6.1.8.1. Technical specifications
25
•
Height.............................................................................................................................................................................................................................12 m
•
Material.......................................................................................................................................................................................................................... Steel
•
Composition.......................................................................................................................................................................................................Sections
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6.1.9. Converter
The electrical energy that exits the generator (alternate current) does not meet the specifications required to be injected
directly into the grid. Therefore, it has to be transformed into consumption parameters by a frequency converter. Ennera
has designed and developed a converter that adapts the electrical energy from the generator into grid conditions (230V
and 50 Hz). The design of the generator-converter unit optimises production throughout the operating process. Improved
performance is obtained by eliminating the transformer This guarantees isolation by means of active monitoring of
possible failures and reducing the direct current component injected into the grid to a minimum, thus complying with the
requirements established by regulations governing grid connection.
The converter includes detailed control software that ensures that the rotation speed of the blades is always optimal
for production and loads. The design also ensures that power production can commence at very low rotation speeds and
detects wind speeds that are too high to produce power. All this is achieved without the need to include anemometers
or rotation speed sensors.
In the wind turbine design, the converter is located at the foot of the turbine to prevent vibrations and high temperatures.
Thus, the useful life of the converter is extended.
The converter not only controls turbine operation, but also stores the registry of failures and communicates the
information needed by the user and the installer through the monitoring centre.
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Figure 14. Converter architecture and assembly.
6.1.9.1. Technical specifications
27
•
Temperature range.......................................................................................................................................................................-10ºC to +45ºC
•
Nominal power.....................................................................................................................................................................................................3.6 kW
•
Rated voltage........................................................................................................................................................................................................ 230 V
•
Rated frequency........................................................................................................................................................................50 Hz; THD < 2%
•
Maximum yield.......................................................................................................................................................................................................... 95%
Product Manual
windera s
PRODUCT
SMALL WIND POWER
SYSTEMS
SYSTEM
DESCRIPTION
MANUAL
6.1.10.Monitoring and communications
The monitoring and communications system is the centre of operations of the installation. Its purpose is to provide
customer access at all times to the operation information of the installation. All this information is sent by a modem
installed in the converter, through the converter antenna using a GPRS protocol to a website protected by a password.
The three main areas of information included in the monitoring centre are as follows:
•
Financial.
•
Meteorological.
•
Technical and environmental.
6.1.10.1. Financial information
The financial information can be daily, weekly, monthly, annually and accumulated from the beginning. The
data visible to the customer are as follows:
•
Accumulated savings in euros: The customer will be able to see how much money he is saving each year
(self-consumption or net metering) and income (FIT).
•
Accumulated payback: A graph will display the percentage of the initial investment that has been
amortised.
6.1.10.2. Weather information
This monitoring and communications application shows the weather forecast for the next few days. The
following information is available:
28
•
Average wind speed.
•
Wind direction.
•
Temperature (Celsius).
•
Solar radiation.
•
Cloud cover.
•
Precipitation.
•
Atmospheric pressure.
Product Manual
windera s
PRODUCT
SMALL WIND POWER
SYSTEMS
SYSTEM
DESCRIPTION
MANUAL
6.1.10.3. Technical and environmental information
6.1.10.3.1.TECHNICAL INFORMATION
The technical information available to the customer is as follows:
•
Wind turbine information (name, serial number, installation date, power installed, years of warranty, etc.).
•
Power generated: This information is obtained from the monitoring centre's database (in kWh)
accumulated over a variety of time periods. A table will be displayed with the mean consumption of the
home/firm as a reference.
•
Energy independence.
•
Operation: Graphs will show the various operating modes that are recorded in the monitoring centre.
6.1.10.3.2.ENVIRONMENTAL INFORMATION
Lastly, the customer will have the necessary environmental information available at all times:
29
•
CO2 saved daily, weekly, monthly, annually and accumulated.
•
Car-equivalent (km driven).
•
Tree-equivalent: The customer will be able to add trees to "his" mountain; that is, the drawing of a
mountain in his customer area will be gradually filled with trees.
Product Manual
windera s
PRODUCT
SMALL WIND POWER
SYSTEMS
SYSTEM
DESCRIPTION
MANUAL
6.2. OPERATION
Wind power consists in obtaining electrical energy from mechanical energy generated by the effect of wind on the
blades.
The Windera S small wind turbine is a system of blades coupled to a rotor with permanent magnets. Under the effect of
the wind, the blades rotate jointly with the rotor, generating a mechanical movement that produces electrical energy by
interacting with the magnetic field created by the magnets. As its function indicates, this system is called generation.
The installation is connected to the electrical grid, so it requires a converter to adapt the properties of the generated power
to those of the grid. It also has an antenna to transfer information to the website by means of GPRS communications.
Thanks to the Windera S system, the generated energy is transported through the grid to the user's home or company.
The following figure shows a diagram of how the Windera S operates.
Figure 15. Windera system operation.
For customer convenience, the small wind turbines are equipped with a monitoring system that provides efficient
management and monitoring of the installation. Ennera operators have access to the system via the web environment,
so they can know the condition of the components at all times and whether maintenance tasks are required.
In addition, the system is equipped with an emergency braking system that is used to stop the rotor blades safely to
avoid materials from being damaged or people from being injured.
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Product Manual
windera s
PRODUCT
SMALL WIND POWER
SYSTEMS
SYSTEM
DESCRIPTION
MANUAL
The Windera S small wind turbine is designed to operate without user revision. If the system detects any problems, it will
shut down automatically, so it can be left unattended.
In case the user wants to stop the Windera S, the converter has 2 buttons for that: Controlled stop button and emergency
stop button.
Figure 16. Controlled stop button (left) and emergency stop button (right).
The user can stop the Windera S with any of those buttons. The emergency stop is faster than the controlled stop.
The overspeed protection ensures that the small wind turbine does not exceed the maximum rotation speed under
high wind speed conditions. These conditions are specified in standard IEC 61400-2 for Class III small wind turbines
(reference wind speed 37.5 m/s and 50-year gust of 52.5 m/s at hub height).
Emergency braking works at three levels:
•
In the event of wind gusts: The control adjusts the speed, reducing blade rotation speed and aerodynamic
torque.
•
In the event of wind speeds that are too high to produce power: The control adjusts the turbine to
a controlled number of revolutions. Once the rotation speed has been reduced, the electrical brake is activated,
taking the small wind turbine to idling speed at which it can withstand the wind loads safely.
•
In the event of failures in the electrical grid or other abnormal system conditions: A redundant speed
protection is enabled, consisting in a combination of electrical braking and the patented mechanical centrifuge
braking system. The electrical brake is activated first. If the wind conditions are such that the electrical brake is
not enough to stop the turbine, the centrifuge brake is activated; this prevents the turbine from exceeding the
maximum design speed and stops it in safe conditions
6.2.1. Emergency stop
By pressing the emergency stop button at the converter front the turbine produces an emergency shutdown. A short
circuit in three phases of the generator will stop the turbine. The turbine is not blocked; it can be rotating at very low
rotating speed.
6.2.2. Controlled stop
The purpose of the controlled stop is to stop the wind turbine smoothly and safely without overloading any of the
Windera S components. The rate of rotation speed reduction applied to the turbine is 10 rpm/s. Wind turbine speed slows
gradually until it is practically stopped. This is when the electrical brake is activated (generator short-circuit), with the
purpose of stopping the turbine completely or letting it rotate at idling speed and remain in those conditions.
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Product Manual
windera s
PRODUCT
SMALL WIND POWER
SYSTEMS
SYSTEM
DESCRIPTION
MANUAL
The control system of the Windera S can protect the wind turbine from working at high winds. There is an algorithm that
detects the high wind speeds and in this case, the control stops the turbine and electrical brake is activated.
In case of very high wind speeds, if the electrical brake is not able to stop the turbine, there is a centrifugal brake that
will stop the turbine.
In case of emergency, the Windera S can be stopped by either using the controlled stop button or emergency stop
button.
Figure 17. Controlled stop push button.
6.3. WINDERA S GENERAL SPECIFICATIONS
32
•
Type..................................................................................................................................................................................................... Upwind connected to grid
•
Generator.................................................................................................................................................................Permanent high-efficiency magnets
•
Rotation speed range..............................................................................................................................................................................................50-280 rpm
•
Grid connection...........................................................................................................................................................Single-phase AC 230 V to 50 Hz
•
Power at nominal wind speed........................................................................................................................................................................................3.2 kW
•
Temperature range.............................................................................................................................................................................................-15ºC to +45ºC
•
Start-up speed..........................................................................................................................................................................................................................3.5 m/s
•
Cut-out speed...........................................................................................................................................................................................................................2.5 m/s
•
Nominal wind speed.........................................................................................................................................................................................................10.5 m/s
•
Maximum operating speed...............................................................................................................................................................................................25 m/s
•
Emergency braking system..................................................................................................................................... Electrical and centrifuge brake
•
Blades.........................................................................................................................................................3 carbon fibre, fibreglass and epoxy blades
•
Tower....................................................................................................................................................................................................................................................12 m
•
Rotor diameter...........................................................................................................................................................................................................................4.36 m
•
Orientation system......................................................................................................................................................................................Passive with vane
•
Rotation speed control..............................................................................................................................Variable speed with electronic control
Product Manual
windera s
PRODUCT
7.
SMALL WIND POWER
SYSTEMS
MANUAL
COMPETITIVE
ADVANTAGES
AND INNOVATIONS
COMPETITIVE ADVANTAGES AND INNOVATIONS
7.1. COMPETITIVE ADVANTAGES
The advances in the wind power market in recent years have achieved a marked improvement in wind turbine
performance, along with a reduction in the cost of the power generated; to this, Windera small wind turbines add the
following advantages versus the competition:
•
Windera small wind turbines require very little maintenance because they are monitored from a web environment
by Ennera operators. Thus, they can operate for long periods of time without any interruptions.
•
The innovative design of the Windera small wind turbine achieves lower noise emissions than other small wind
turbines.
•
The Windera system has 400 configurable parameters that obtain optimum yield from available wind power.
7.2. INNOVATIONS
33
•
The blades are designed with technology used in the aeronautical sector to increase efficiency.
•
The winglet on the rotor blades reduces aerodynamic resistance and therefore increases the available wind power.
•
Optimal control to make the most of the wind power.
•
The Windera monitoring system can be used to display and manage the operation of the Windera S and to know
the amount of energy being generated at all times.
•
The customer can find all kinds of parameter values, both current and historical through the on-line application.
•
There are 50 alarms for early detection of failures and anomalies.
Product Manual
windera s
PRODUCT
8.
SMALL WIND POWER
SYSTEMS
INSPECTIONS AND
MAINTENANCE
MANUAL
INSPECTIONS AND MAINTENANCE
Although the small wind turbine is monitored at all times by Ennera operators from the web environment to perform
required maintenance tasks, the reliability and features can be improved by regular inspection of the system.
The maintenance of the Windera S wind turbine must be carried out by trained personnel only.
The following safety measures must be taken into consideration before performing an inspection:
DO NOT MANIPULATE THE STRUCTURE OF THE SMALL WIND TURBINE IN THE EVENT
OF A BREAKDOWN.
IF A PROBLEM IS DETECTED, CALL THE TECHNICAL SERVICE.
DO NOT PERFORM INSPECTIONS IN ADVERSE WEATHER CONDITIONS OR WHEN WIND
SPEEDS EXCEED 10 M/S.
Before performing inspections, refer to Table 1, which lists the most common problems that can
occur in the small wind turbine.
8.1. VISUAL INSPECTIONS
The following steps should be taken when a visual inspection is requested:
1.
Shut down the small wind turbine.
2.
Perform a visual inspection in search of serious notches and cracks in the blades and winglet.
If there are conspicuous cracks or notches on the blades, these can cause serious
damage and failures in the turbine. If the blades are damaged, call the customer
service.
3.
Inspect the tower and structure of the small wind turbine to check for structural damage or loose parts.
If the structure of the small wind turbine is damaged, call the customer service.
4.
34
Start up the small wind turbine again.
Product Manual
windera s
PRODUCT
SMALL WIND POWER
SYSTEMS
INSPECTIONS AND
MAINTENANCE
MANUAL
8.2. NOISE INSPECTIONS
1.
Operate the small wind turbine at nominal speed and check that it does not emit mechanical noises such as
metallic banging or rattling.
2.
Make sure that none of the components are subject to notable vibration. The turbine should operate smoothly
and free of disturbances.
If strange noises or strong vibrations are detected, shut down the small wind turbine
and call the customer service.
8.3. MAINTENANCE
Although the Windera S has been designed for a service lifetime of 20 years, Ennera Energy and Mobility recommends
Windera S wind turbine be checked on an annual basis to make the maintenance procedure.
The maximum wind under which the maintenance procedure may be carried out is Vmaint= 10 m/s.
The design of the Windera S wind turbine includes simple, robust components in order to minimise maintenance tasks
during its useful life. Nonetheless, the environmental and electrical connection conditions can vary greatly from one site
to another. Therefore, Ennera has established a proactive process that maximises the profitability of the installation. The
first phase consists of a periodical check by an operator who visits the installation, which is covered by the warranty.
In addition, if the installation requires an inspection due to poor conditions detected by the monitoring centre or the
user, the technical team will get in touch with the user to agree on a date to perform the revision, as established in the
maintenance contract.
Wind turbine operation will be monitored by the monitoring centre to know the status of the turbine at all times
and access the history log of registered alarms. Our technicians can use the communications module to access the
installation remotely, analyse its status and organise any corrective measures that may be required. This process
minimises operational costs by using preventive maintenance to reduce breakdowns, early remote analysis to reduce
repair times and thus maximise installation production times.
Proper maintenance is essential in a product with a useful life of 20 years and the corresponding time intervals will
depend on the characteristics of the installation site.
The Ennera website www.ennera.com provides further information on maintenance of the Windera
S. If you have any questions or suggestions, please do not hesitate to call Ennera at the toll-free
number: 900 700 034 or contact us via e-mail at [email protected].
For further information on recommendations for maintenance, please refer to the installation and
maintenance manual.
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Product Manual
windera s
PRODUCT
9.
SMALL WIND POWER
SYSTEMS
TROUBLESHOOTING
MANUAL
TROUBLESHOOTING
The following precautions should be taken before taking any specific troubleshooting measures:
DO NOT MANIPULATE THE STRUCTURE OF THE SMALL WIND TURBINE UNDER ANY
CIRCUMSTANCES. IF A PROBLEM IS DETECTED, CALL THE TECHNICAL SERVICE.
The following table shows the most common problems that can occur in small wind turbines, as well as their causes and
how to solve them.
Table 1
Problem detected
Possible cause
THE EMERGENCY BRAKE
BEEN
ACTIVATED,
DUE
THE SMALL WIND TURBINE REMAINS
STILL ALTHOUGH THERE IS WIND.
Solution
HAS
TO:
• TEMPORARY ADVERSE WEATHER
CONDITIONS.
• FAILURES IN THE ELECTRICAL GRID
OR OTHER ABNORMAL SYSTEM
CONDITIONS.
THE SMALL WIND TURBINE MAKES
OCCASIONAL MECHANICAL NOISES.
FRICTION BETWEEN COMPONENTS
OR DAMAGED BEARINGS CAN CAUSE
VIBRATIONS AND EXCESS LOADS.
THE SMALL WIND TURBINE MAKES
AN UNUSUAL NOISE, SUCH AS WHISTLING OR BUZZING.
ROTOR BLADES DAMAGED.
THE ROTOR IS OFF BALANCE, CAUSING THE TURBINE TO MOVE SLIGHTLY
BACK AND FORTH.
BLADES DAMAGED.
THE TURBINE RATTLES DURING ROTATION, ESPECIALLY AT LOW SPEEDS.
• BEARINGS DAMAGED.
• ROTOR MISALIGNED.
ICE ACCUMULATED ON THE BLADES.
THE ROTOR ROTATES VERY SLOWLY.
SHORT-CIRCUIT BRAKE ACTIVATED
DUE TO GRID FAILURES OR OTHER
ABNORMAL SYSTEM CONDITIONS.
SHORT-CIRCUIT BRAKE ACTIVATED
DUE TO HIGH WIND SPEEDS.
THE ROTOR DOES NOT TURN.
36
MECHANICAL FAILURE IN THE ALTERNATOR.
WAIT UNTIL THE WEATHER CONDITIONS IMPROVE AND CHECK THAT
THE BLADES OF THE SMALL WIND
TURBINE START ROTATING AGAIN.
IMPLEMENT A CONTROLLED STOP OF
THE CONVERTER AS INDICATED IN
SECTION 6.2.2 AND CALL THE CUSTOMER SERVICE.
IMPLEMENT A CONTROLLED STOP OF
THE CONVERTER AS INDICATED IN
SECTION 6.2.2 AND CALL THE CUSTOMER SERVICE.
IMPLEMENT A CONTROLLED STOP OF
THE CONVERTER AS INDICATED IN
SECTION 6.2.2 AND CALL THE CUSTOMER SERVICE.
IMPLEMENT A CONTROLLED STOP OF
THE CONVERTER AS INDICATED IN
SECTION 6.2.2 AND CALL THE CUSTOMER SERVICE.
WAIT UNTIL THE WEATHER IMPROVES.
IMPLEMENT A CONTROLLED STOP OF
THE CONVERTER AS INDICATED IN
SECTION 6.2.2 AND CALL THE CUSTOMER SERVICE.
WAIT UNTIL THE WIND SPEED DROPS
AND CHECK THAT THE BLADES OF
THE WIND TURBINE START ROTATING
AGAIN.
IMPLEMENT A CONTROLLED STOP OF
THE CONVERTER AS INDICATED IN
SECTION 6.2.2 AND CALL THE CUSTOMER SERVICE.
Product Manual
windera s
PRODUCT
SMALL WIND POWER
SYSTEMS
FREQUENTLY
ASKED QUESTIONS
MANUAL
10. FREQUENTLY ASKED QUESTIONS
10.1. GENERAL QUESTIONS
•
Can the small wind turbine be left unattended?
Yes, the small wind turbine is designed to operate without user revision. If the system detects any problems, it will
shut down automatically.
•
Are small wind turbines noisy?
The Windera S small wind turbine emits noise within acceptable ranges, since its nominal rotation speed is
between 50 and 230 rpm.
•
For how long do small wind turbines produce electricity?
This depends largely on the chosen installation site, mean wind speed and how constant the wind is.
In an adequate installation site, a small wind turbine produces electricity 75% of the time, although not always at
nominal power. In a normal year, it produces 20% to 30% of the electricity produced at nominal power operating
non-stop. This value is known as the capacity factor.
•
How long does a small wind turbine last?
The Windera small wind turbine is designed to last for more than 20 years. This is due to its robust design, the
quality of its materials and anti-corrosion treatments and to a totally sealed design that prevents humidity and
particles from entering the system.
•
Can birds fly into small wind turbines?
It is highly improbable that a bird will fly into the blades of the Windera small wind turbine because migrating flocks
fly at greater heights during their journeys.
10.2. TECHNICAL QUESTIONS
•
How does a small wind turbine work?
The blades use the force of the wind to generate a mechanical torque in the generator, which in turn generates
three-phase electricity depending on the rotation speed and the force exerted on its shaft by the blades. The
electricity generated passes to the converter and is transformed into single-phase electricity so that it can be
injected into the electrical grid in low-voltage distribution conditions.
•
Is it necessary to install protection between the small turbine and the converter?
Never, the converter performs all the necessary protection functions. If a protective measure is installed between
the turbine and the converter and it causes the electrical connection to cut off, the turbine will continue to operate
in no-load mode, causing irreparable damage to the small wind turbine.
•
How do I know the power being delivered by the small wind turbine?
You can find out the power being delivered by the wind turbine by accessing the monitoring web environment.
•
What is the maximum wind speed that the small wind turbine can withstand? Should the system be shut down
during a storm?
The Windera S small wind turbine is designed to operate unattended in storm conditions thanks to its control
system and overspeed protections.
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Product Manual
windera s
PRODUCT
SMALL WIND POWER
SYSTEMS
RECYCLING
MANUAL
11. RECYCLING
Ennera will make the necessary repairs throughout the useful life of the Windera S. If any
of the components require replacement, our technicians will collect the old component
and ensure that it is disposed of properly.
In accordance with European Directive 2002/96/CE regarding electrical and electronic
device waste and its application in Spanish law, used electrical devices must be collected
separately and recycled in an environmentally friendly manner. Therefore, when the
time comes, please contact the local authorities responsible for proper waste disposal
and ensure that the entire turbine is disposed of correctly.
The Windera S is designed and manufactured according to European Directive 2002/95/
CE (RoHS), so it does not contain hazardous substances.
Directivr 2002/95/CE (RoHS) restricts the use of lead, mercury,
cadmium, hexavalent chromium, PBB (polybrominated biphenly) and
PBDE (polybrominated diphenyl ethers).
Avoid possible environmental and health hazards by disposing of this product adequately.
Recycling of materials will benefit the preservation of natural resources.
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Product Manual
windera s
PRODUCT
SMALL WIND POWER
SYSTEMS
ANNEXES
MANUAL
12. ANNEXES
12.1. ELECTRICAL CONNECTION DIAGRAM
Figure 18. Single line electrical diagram.
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Product Manual
windera s
PRODUCT
SMALL WIND POWER
SYSTEMS
ANNEXES
MANUAL
12.2. GENERAL DIMENSIONS DRAWING
Figure 19. General dimensions in mm.
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Product Manual